1. Rajiv Malhotra
16 D, Dayanand Nagar, Ghaziabad(201001),Phone-9818217883,
E.Mail : rajivmalh006@gmail.com
______________________________________________________________________________________
Professional Summary
 With over 20 years of Managerial experience in Quality Assurance, TQM and Production
Management.
 National Award winner for Power Distribution System Improvement Project
 Well versed with quality management systems Like ISO/TS 16949:2009 and 14001 :
2004
 Process enhancement techniques like TPM, lean manufacturing with SPC, Six Sigma,
Kaizen, 5S, 3M.
 Area Coordinator for TPM implementation with the help of TPM Club of India.
 Excellent analytical & problem solving skills with latest Statistical tool like Gauge R&R,
FMEA, DOE, Cp /Cpk study, Multi Vari Chart, Control Chart and Control Plan.
 Certified Internal auditor and attended Lead auditor course of ISO 9001;2008 &
14001 : 2008
 Understand the customer issues and resolve them through 8D & system building.
 Certified Six Sigma Green Belt with proven ability of successfully handled 54 Green Belt
projects as a Leader with respect to Capability improvement, cost reduction &
quality enhancement.
Core Competencies
Quality assurance: Ensuring compliance with quality control standards like ISO/TS
16949:2009, 14001:2008, for improvement in the quality of products. Identifying and
resolving process issues & Reducing Customer end rejection through utilization of techniques
like QFD, Six Sigma, DOE, Gauge R&R and FMEA for line production. Effective Customer
related inspection to ensure product quality before dispatch. Analysis of customer complaints
and improving the Process capability of line. Corrective and preventive action for customer
related complaint. Improving line performance through Incoming material Quality inspection,
vendor evaluation and vendor development. Addressing all environmental issues, Aspects and
their Impacts, Plan to reduce the impacts.
Production Management: Overseeing production related tasks including planning, control
and trouble shooting. Developing new process concepts for production optimization, yield
improvement and develop plans for reducing rejection/ rework/ wastage, etc.
Materials Management: Streamlining the systems and procedures for effective inventory
control for ensuring availability of material to meet the production targets.
Maintaining WIP standards at shop floor. Maintaining FIFO system at all machines and
inventory areas.
Team Management: Identifying skill levels of operators, Multi skilling of operators through
proper training, delegating area ownership in their respective areas. Active involvement of all
operators for improving resource utilization, motivating team for suggestions and kaizen
approach.

2. Job Responsibilities
Quality Assurance and MR
• To work as a single window person for Phillips, Honda Motor Cop, Osram, INEL,
• Solely responsible to customers from product development to after sales service support.
• Business growth and sustainability by achieving customer targets.
• Heading the team for 5 Quality engineer and 32 Quality operators.
• Ensuring compliance with quality Management system like ISO/TS16949:2009,and 14001:
2004.
• Take Management review for every Department.
• Conducting ongoing process capability study and calculate Cp, Cpk of the processes under
SPC
• Responsible for reducing internal rejection Myler Line.
• Responsible for taking and implementing corrective and counter measure for customer
complaints.
• Identifying and resolving process issues & Reducing Customer end rejection through
utilization of techniques like QFD, Six Sigma, DOE, Gauge R&R and FMEA for line
production.
• Product CTQ audit, Process CTQ audit and Quality system audit at vendor end.
• Audit of corrective action and preventive action implementation at vendor end.
• Prepare monthly Quality MIS of all incoming material.
• Vendor Evaluation and vendor rating on quarterly basis.
Effective Customer related inspection to ensure product quality before dispatch.
Projects Undertaken
Title To make Press as Manager’s Model Machine
Role Team Leader
Members Maint. Manager, Area Manager, Shift Engineer, Maint Engineer, Three
Operators & Two Fitters
Theme Zero Break Down, Zero Defect, Zero Accident
Details First we meet as a Team together and make clarity on TPM Concept.
After that we decided daily 30 minutes to be spend on cleaning of press. Purpose of cleaning
was identified defects besides cleaning. We put Red and White tags. Make the abnormality list
and removed it. Made CLIT Sheets and tools for that purpose. Do Why-Why for defects
Generation, Identified leakages and plugged it. Identified source of dust and also plugged it.
Do identification on all parts and made it visual machine. Completed Four Pillars of TPM at
this Machine
Benefit No break down & zero accident from last one and half year. Rejection level decrease
from 7500 PPM TO 150 PPM
Title To Eliminate Mask Peel Off at Blackening Furnace From 3% to Zero
Role Team Leader
Members Process Engineer, Maintainace Engineer, One Fitter, Three Operators
Theme Wastage Control
Details In this project in analysis phase it was found after DOE that if temperature of
recalculating water kept above 38 degree then there would be no peel off. Again in analysis it
was found that there was a chiller unit in utility for cooling of this water having no temp
controller so that in night temp of this water goes down to 38 degree and moisture comes
with gas which create peel off.
Benefit Rs 50 lacs per annum.
Title To make Winding Area as Model Area for 5S-3M
Role Team Leader of One Sub Zone

3. Members Line Manager, Area Manager, Shift Engineer, Maint Engineer, Three
Operators & Two Fitters
Theme Basic Process Discipline
Details First we identified all things which we required for running of smooth production and
put red tag on all other items which were not in used. Send them to Red Tag Area. After that
marked the place for rest the items. Made the cleaning schedule for these items.
Implemented & Documented the all kaizens. In 3M Identified all mura, muri & muda’s and
removed these through small small modifications. Implemented 3C concept. On later stage
100% involvement of each member of area Through suggestion scheme
Benefit Rs. 30 lakh/annum by decreasing WIP on floor, Film wastage from 700 Kg to 250 Kg
per month, Increased in productivity by 80 K/day, Break Down Time from 5.5 hours/month to
35 min/month, Area recovered by 160 sq meters at shop floor & 50 sq meter at scrap yard.
Title To increase the welding electrode life from 3 times to 6 times
Role Team Leader
Members Asst. Manager Engg. Production Engineer, Two M/C Operator.
Theme Cost Reduction
Details In Analysis phase it was found after using Fish Bond Diagram and Why-Why
Analysis that electrode was hollow so that after three times repairing it would be scraped . It
was also come out that stroke length of cylinder was 30 mm which was also constraint. So
Shift the electrode holder mounting to reduce the gap in home position. Before it FMEA done
for this.
Benefit Rs. 4 lakh/ annum.
Career Highlights
Since July 2007 with Deki Electronics as Sr.Manager QA
An ISO/TS 16949:2009 & 14001:2004 Certified largest film capacitor company in India.
Improve the plant yield from 90% to 97% by reducing the process variations.
Standardization of two critical processes.
MR for ISO/TS 16949:2009 and ISO 9001:2008
Elimination Electrical Rejection through process optimization.
Reduced the customer complaints from 45 per annum to 8 per annum.
Vendor Development through process audit and used their material Direct on Line.
From Nov 94 to July 07 with Samtel Color Ltd as an Assistant Manager
An ISO 9001:2008 certified manufacturer of colour picture tubes with a turnover of Rs. 1000
crores
- Certified Six Sigma Green Belt from Samtel Six Sigma Cell and completed five projects
in two years on Quality improvement, cost reduction & Productivity improvement.
- Following Green belt Projects Successfully completed as a leader.
o Reducing ‘Q’ Variation of Shadow Mask from 600 micron to 300 micron.
o Reducing BS Rejection in CPT from 8% to 3% at 1st
shot inspection.
o Improving Electrode Life of Spot Welders 3 times by DOE.
o Improving Frame deflection Cpk from 0.97 to 1.42.
- Reduction of Line Rejection due to incoming material complaint from 2008 PPM to 350 PPM
by effective Process audit at vendor end.
- Reducing the line Rejection Jerk from 15 to 3 jerk per year By effective PFMEA and continues
Audit of control Plan.
From May’94 to Nov ’94 with Phoneix Electric India Ltd as Supervisor Trainee
First and largest manufactures of Halogen Lamps in India
Improve the production of lamps from 2008 to 2400 per shift.
Reduce the wastage by training to operators.

4. Make the SOP for Filament Solderering.
Trainings
Attended several in-house trainings on Six Sigma, ERP, TPM, 5S, Electro Pneumatics,
Hydraulics, AMT, Lead Auditor EMS, Internal Auditor QMS and EMS, New Seven QC
Tools, APQP PPAP.
Education
2010 B.Tech in Industrial Engineering and Management (Specialization in TQM) with 78%
. marks
2008 One Year Basic Course in Quality Management from PTU.
2003 Six Sigma DMAIC Green Belt Certification
1994 Diploma in Mechanical Engineering from Govt. Polytechnic Ghaziabad with 70% marks
1991 Class XII from U.P.Board with 70% PCM
1989 Class X from U.P.Board with 67% Marks
Activities and Society
1. Worked for improvement of electricity supply in Ghaziabad as a Head of Electricity
Management Committee of RWA Federation.
2. Working for Quality and Affordable School Education.
Personal Detail
Father’s Name : Shri B.K.Malhotra
DOB : 15th
Sep. 1974
Language Known : Hindi, English, Punjabi
Salary drawn : 10.5 Lacs per annum
Salary Expected : Negotiable
(Rajiv Malhotra)